Chrysler Full-Size Trucks 1989-1996 Repair Guide

Valve Lifters

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The hydraulic valve lifters are also known as "tappets,'' and this term will be used interchangeably in this guide.

REMOVAL & INSTALLATION

2.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cylinder head cover.
  4.  
  5. For each rocker arm, rotate the cam until the base circle is in contact with the rocker arm. Depress the valve spring using tool No. MD-998772A. Slide the rocker arm out. Keep all rocker arms in order for installation in the exact same sequence.
  6.  
  7. Remove the hydraulic valve lifter.
  8.  

To install:
  1. Install the hydraulic lifters. Make sure that the adjusters are at least partially full of oil.
  2.  
  3. Rotate the cam until the base circle is in contact with the rocker arm. Depress the valve spring and slide the rocker arm in place.
  4.  

Keep the rockers in the original order. It is possible for the valve spring retainer locks to become dislocated when depressing the valve spring. Check to make sure the locks are in their proper location.

  1. Install the vapor curtain, if equipped, and the cylinder head cover.
  2.  
  3. Connect the negative battery cable.
  4.  

V6 and V8 Engines

See Figures 1, 2, 3 and 4

See Figure 5



Click image to see an enlarged view

Fig. Fig. 1: A magnet is useful in removing lifters from their bores

  1. Remove the cylinder head and rocker assembly keeping all parts in original order.
  2.  
  3. Once the rocker assembly and pushrods are removed, use tool C-4129-A, or equivalent, to remove the valve lifters from their bores. Pull the tappet out of the bore with a twisting motion. Keep the tappets in order so they can be installed in their original bores.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Stuck lifters must be freed using a slide hammer type lifter removal tool

To install:
  1. Lubricate and install the lifters in their original locations. Make sure the oil feed hole in the side of the lifter body faces up (away from the crankshaft.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of hydraulic tappet assembly assembly-2.5L engine

  1. Install the rocker arm and shaft assembly.
  2.  
  3. Install the vent cover, distributor, start the engine.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of hydraulic tappet assembly assembly-V6 engine



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Fig. Fig. 5: Roller tappet aligning yoke and retainer-V6 engine

V10 Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and cylinder head cover.
  4.  
  5. Remove the rocker arms assembly and pushrods. Label or organize the pushrods to enable installation in the original location.
  6.  
  7. Remove the upper and lower intake manifold.
  8.  
  9. If the end tappets are to be removed, remove the cylinder head.
  10.  
  11. Remove the yoke retainer spider and tappet aligning yokes.
  12.  
  13. Pull the tappets out of the bore with a twisting motion. Label or organize the tappets to enable installation in the original location.
  14.  

Refer to the Overhaul procedure which follows.

To install:
  1. Lubricate the tappets.
  2.  
  3. Install the tappets in their original positions. make sure the oil bleed hole (if equipped) faces FORWARD.
  4.  
  5. Install the alignment yokes and retainer spider. Tighten the bolts to 16 ft. lbs. (22 Nm).
  6.  
  7. If removed, install the cylinder head.
  8.  
  9. Install the pushrods in their original location.
  10.  
  11. Position the rocker arm assembly on the pedestal and align the pushrods. Install the bolts and tighten to 21 ft. lbs. (28 Nm).
  12.  
  13. Install the lower and upper intake manifold.
  14.  
  15. Install the cylinder head cover and air cleaner.
  16.  

OVERHAUL



Unless properly experienced and equipped, reaming the tappet bores should be left to a qualified shop.

Tappets may be overhauled by prying out the plunger retainer spring clip and disassembling the components. Keep all parts in order. Clean the varnish deposits from inside the tappet body above the plunger cap. Clean all parts in solvent which will remove varnish and carbon. If the plunger shows signs of scoring, wear or sticking and the valve is pitted, or if the valve seat on the end of the plunger indicates any condition which would prevent the valve from seating, ream the bore size and replace the tappet assembly with the next oversize.

 
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